john delvaux - national energy technology library/events/2015/utsr/tuesday... · john delvaux ©...

© 2015 General Electric Company. All rights reserved.

EducationBEME Auburn University 1985MSME University of Florida 1994

CareerTechnical Leader Ceramic Matrix Composites – 2009+Aeromechanics Growth Leader – 2005Technical Leader Gas Turbine Technology Lab - 2000Agilis Technical Leader – 1998Pratt and Whitney Senior Design Engineer - 1985

Technical expertiseTurbine Design and TestTurbine Airfoils Aeromechanics

Accomplishments: CMC Field Endurance RecordF-Class GT Durable CompressorF135 Fan Blade DesignF136 Compressor Blade DesignAS907 Low Pressure Turbine Blade DesignBoard Certified Mechanical EngineerSix Sigma Black BeltSignificant Invention DisclosuresClemson University Capstone Coordinator

ActivityHikingMotor SportsAuburn University Engineering Advisory Board

John Delvaux

© 2015 General Electric Company. All rights reserved.

• GE CMC

• Accomplishments

• GEA

• GE Power Nozzle

© 2015 General Electric Company. All rights reserved.

GE Ceramic Matrix Composite (CMC) Processing

Wet DrumWinding

CoatingCVD FiberFiber

SlurryMatrix

LaminateLay-Up and

Preform Fabrication

Melt Infiltration

Prepreg

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Microstructure of Prepreg MI Composites

FiberFiber

Coating

SiC-SiMatrix

• Fibers Homogeneously Distributed; Vf = ~25%• Separated Fibers and Fiber Coatings• ~2-3% Matrix Porosity

© 2015 General Electric Company. All rights reserved.

Environmental Barrier Coating (EBC) EBC needed for turbine applications to prevent silica volatilization and surface recession from water vapor in combustion gas

SiO2 + H2O Si(OH)x (gas)

Baseline System Advanced system• Retain Si bond coat • RE silicate layers

CTE match recession resistance

© 2015 General Electric Company. All rights reserved.

GE & DOE Advancing Development of CMC Material for Power Generation

laminate structure

Increased material temperature capability …… efficiency, output, reduced COE

Years =>

High-temp material testing; 100,000 hrs …… & toughness demonstrations

Field service demonstration …… >20,000 hrs on 7FA shroud set

DOE 2014 phase 1 award …… High Temp CMC Nozzles

GE 7FA Shroud Installation

CMC

Reference: Aviation CMC nozzle

toughness demo

© 2015 General Electric Company. All rights reserved.

Combustion Liner~30 cm dia x 27 cm length12,855 hrs, 45 cyclesSolar 5 MW gas turbine2005 - 2006

Shroud Durability Test 12930 hrs, 552 cycles2006 - Continuing

Shroud Durability Test 221740 hrs, 126 cycles2011 - 2014

Shroud~8 cm x 15 cm first stage shroud96 per full set – 160 MW machine

Nearly 44000 hrs of CMC Field Experience

First Shroud Demo 160 MW machine5366 hrs, 14 cycles 2002-2003

Stage Shroud Ring47cm dia1000 hrs2 MW Machine 2000

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Typical 3-stage F-class TurbineTypical Customer Brochure

First GE Power Application

© 2015 General Electric Company. All rights reserved.

DoE funding for CMCs… Big Impact

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Aviation GE Power

Powering the world… opportunity for CMCs

• Engine Orders• Build Factories

Raw Fiber Fiber Coating & Tape

Correa said. For GE, “this is very much past the science experiment and engineering marvel”

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Industrial Turbine Applications

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Mission Uniqueness… GT Durability ChallengeS

urfa

ce T

emp

(°F)

Log Time (hours)

| | | |

10 100 1,000 10,000 100,000

Aviation~25,000h~15,000cy, 0.03-10h holds

take-off

max climb

climb

cruise

Power Gen~25,000h~1,000cy, 10-100h holds

HA Class

F Class

Need to demonstrate capable designs

© 2015 General Electric Company. All rights reserved.

Nozzle Concepts

1

Select AttributesSimple CMC airfoils… high yieldSealing complexity… performance riskLoaded CMC… life risk

CMC… A key technology for the 65% efficient machine

Cantilevered CMC airfoil… low stressLoaded metal… life riskID endwall gaps… performance risk